Prefabricated bathroom unit



July 12, 1955 F. w. BUSCH PREFABRICATED BATHROOM UNIT 5 Sheets-Sheet 1Filed April 16. 1949 INVENTOR. FRANK w.BuscH ATTOR EY 5 Sheets-Sheet 2F. w. BuscH PREFABliICATED BATHROOM UNIT July 12, 1955 Filed April 16.1949 ax: \\\x' li a\\ I'I1.:'..J"

INVENTOR.

FRANK w. BUSCH BY W ATTORNEY July 12, 1955 F. w. BUSCH PREFABRICATEDBATHROOM UNIT 5 Sheets-Sheet 5 Filed April 16. 1949 F IG.

2 INVENTOR. FRANKAV. Busc H ATTORNEY July 12, 1955 F. w. BUSCHPREFABRICATED BATHROOM UNIT 5 Sheets-Sheet 4 Filed April 16. 1949INVENTOR.

FRANK w. BUSCH BY W ATTORNEY July 12, 1955 F. w. BUSCH PREFABRICATEDBATHROOM UNIT.

5 Sheets-Sheet 5 Filed April .16. 1949 LUZ INVENTOR.

FRANK w, BUSCH BY j ATTORNEY United States atent @fice Patented July E2,1955 This invention relates to a prefabricated building unit and moreparticularly to a prefabricated bathroom complete with plumbingfixtures.

An object of the present invention is to provide a prefabricatedbathroom unit which is constructed in such a manner as to facilitate itstransportation as a cubical unit from the factory to construction site;and from the construction site into the building in which it is to belocated, without requiring the necessity or use of cranes, heavyrigging, pipe rollers, or the like.

Another object of the invention is to provide a unitary bathroomstructure which includes, as an integral and basic part thereof, a baseelement including peripheral members which are constructed and arrangedto overlappingly engage and span structural support members provided inthe building which define an opening or well into or over which the unitis to be received or located.

A further object of the invention is to provide a unitary bathroomstructure including a base element which is reenforced in such a manneras to support the floor, wall and ceiling portions of the room, whereinthe floor is constructed in such a manner as to positively preclude thepassage of water therethru.

A further object of the invention is to provide a unitary bathroomstructure the walls and ceiling of which are fabricated from standardpanels, and where in cerrain of the wall panels are fabricated wherebyto define window and linen-storage offsets.

Still a further object of the invention is to provide a unitary bathroomstructure wherein all service connections are available along one sidewall, and wherein the structural relationship of said side wall withreference to the base element of the unit is such as to provide autility shaft non obstructed throughout its length and breadth therebyproviding passageway for accommodating heating, power, water, sewage,electric and other services.

Another object of the invention is to provide a unitary bathroomstructure having the hereinabove described characteristics wherein thewalls are constructed in such a manner as to facilitate the erection ofother permanent building walls in spaced relationship therewith, andwherein the space between such walls may be expeditiously insulated.

Still another object of the invention is to provide a unitary bathroomstructure complete with plumbing fixtures and all piping connections,including water and waste lines, the ends of which are locatedexteriorly of the structure for ease of access for being permanentlyconnected to the conventional Water and waste service lines of thebuilding in which the bathroom is located without requiring the presenceof workmen in the bathroom until after the fixtures thereof have beenconnected to their various service lines after which it may be desiredor necessary to pressure-test the waste line as required by the sanitarycode of certain localities.

Still a further object of the invention is to provide a prefabricatedunitary bathroom structure having the hereinabove describedcharacteristics wherein the toilet waste connection terminates in astandard T, crow foot or similar fitting including a vertical legsecurely anchored relative to the base element for determining thelocation of the stack or riser pipes to be connected to the vertical legthereof.

A further object of the invention is to provide a unitary bathroomstructure which is inexpensive to fabricate, and adapted to bemanufactured using modern mass production techniques.

These and other objects are attained by the means described herein andas disclosed in the accompanying drawings, in which:

Fig. l is a perspective view of a bathroom unit embodying the teachingsof the present invention, shown in an elevated or raised position withreference to the well provided in a building in which it is to bereceived;

vertical section thru the left side of the illustrating certain detailsof construction. horizontal sectional view of the unit of installed inthe well of a building.

4 is an enlarged view illustrating the structural det s of thewindow-sill and window construction comprising a detail of theinvention.

Fig. 5 is a vertical section taken on line 5-5 of Fig. 3.

ig. 6 is a side view of the outer face of the right wall of the unit ofFig. 5 illustrating certain details of construction.

Fig. 7 is an enlarged sectional view of a portion of the left wall ofFig. 3, illustrating certain details of construction.

With reference now to Fig. l, the numeral 8 indicates generally aprefabricated cubical bathroom unit dimensioned to be received withinwell ill provided in a building structure. Well 10 may be defined by aplurality of header members denoted generally by the numerals 12, 14, 16and i3 constructed in any suitable manner.

in the illustration headers 18 are disposed adjacent and parallel withan outer wall, denoted generally by the numeral 19, in which a window isprovided. it should be understood that wall 19 may be fabricated fromany suitable building material, and that, if desired, a suitable ledgemay be provided on the top of a foundation, or made integral with thewall in lieu of headers 18.

The bathroom unit comprises, generally Speaking, at base member or framework 29, a floor 22, side walls 24, and a ceiling 26. With particularreference now to Figs. 1, 3 and 5, it will be observed that base member20 is a substantially U-shaped load bearing frame Work comprising sideangles or members 3%} and an end member 32. A load bearing element 34 isprovided in spanning relationship between side members 30 and spacedinwardly from those ends of members 30 remote from end member 32. Inthose instances in which members 36, 32, and 3 which collectivelycomprise the load bearing frame work 28 are of L-shaped angleconstruction, a portion of the vertical leg or web may be removedadjacent the free ends of side legs 39 for providing flat bearingmembers 36 which are adapted to overlappingly engage headers 16, seeFig. 5.

Members 36 and 32 are dimensioned whereby their respective horizontallegs 61 will overlappingly engage the upper surface of headers 12, idand 18, and load bearing element 34 will be disposed in spacedparallelism with header 16 thereby defining a utility shaft area denotedgenerally by the numeral 4-0, Figs. 3 and 5. A plurality of load bearingelements, such as angles denoted generally by the numerals 4-2 aresecured as by welding to and disposed in spanning relationship betweenmembers 32 and 34, thereby defining a rigid load bearing frameworkconstructed and arranged to be received within and spanningly engage theupper peripheral supporting edges of well ill.

With reference to Figs. 1, 5 and 6, it will be noted .bolts may be usedin lieu of screws 63.

. supported thereon to be transported from place to place,

such as, from the factory onto a truck or other means of conveyance;from the conveyance to the building site and thence from the buildingsite into the building of which the unit is to become an integral part.After the unit structure has been delivered to the building site, it maybe rolled over the sub flooring, or over boards temporarily laid overthe joists and across the well defined by headers 12, 14, 16 and 18.When the members 30, 32 and 34 which define base member 29 of the unitengage these headers the unit will be rigidly and permanently secured inplace without the necessity of further anchorage.

Since each unit is entirely self-contained it may be installed as soonas well has been defined, after which the building may be erected aroundthe unit.

With reference now to Fig. 2, floor 22 may comprise a sheet or layer 59of sound deadening material such as, by way of example, commercialinsulation board be- 7 neath a sheet of plywood 52. A sheet 54 ofwaterproof material, such as aluminum, may be disposed on the uppersurface of plywood 52, and a sheet of linoleum 56 may be secured, as byan adhesive, to the upper face of sheet 54. The resultant compositefloor structure thus formed will be characterized by its inherentstrength and sound deadening characteristics, its water proofness anddurability.

In the preferred embodiment of the invention, the peripheral edges ofthe floor overlappingly engage portionsof members 31 32 and 34 of basemember 26 and rest upon the horizontal legs of angles 42.

In the preferred embodiment of the invention, I secure a U-shapedchannel, defined by laterally spaced sidewalls 60 and a bottom Wall 62,to the upper face of horizontal leg 61 of the base member defined byangles 30, 32 and 34. As illustrated in Fig. 2, bottom channel wall 62may be permanently secured to the base member by means of a suitablefastening element 63, the shank 65 of which may be imbedded in header14. If desired, In this manner I provide a double walled peripheralmember with which the lower ends of a plurality of stud channels areassociated.

Preferably, channels 70 are substantially C-shaped in cross section, seeFigs. 3, 4, and 7, and comprise side and end walls 72 and 74respectively, wherein the free ends of side walls 72 are turned inwardlyas at 76. These channels may be secured to base panel 60 by means ofrivets, screws 78, or other suitable fastening means An L-shaped channelincluding a horizontal leg and a vertical leg 82 may be secured to theupper end of vertical channels 70 by suitable fastening means, such as,by way of example, self-tapping screws 84 or the like, leg 80 beingdisposed in spaced parallelism with bottom wall 62 for providing ahorizontal shelf or ledge engageable by outturned flange 88 of the sidewall panels 86.

The side walls 24 of the structure may be fabricated from lengths ofsheet material formed whereby to provide an elongated panel portion 86,the upper end of which is turned outwardly or rearwardly to provide aflange 88 constructed and arranged to overlappingly engage the uppersurface of leg 80 of the panel which circumscribes the upper ends ofvertical panels 70.

The other end of panels 36 are adapted to be received between theadjacent faces of base channel 60 and sidewalls 72 of channels 76, seeFig. 2. If desired, a trim or finish strip comprising legs 81 and 83 maybe secured in place around the outer edge of the composite floor 22 bymeans of fastening elements 85.

With reference now to Fig. 7 it will be noted that one of the side edgesof elongated panels 86 are provided with an outturned flange 2 whereasthe other edge is turned outwardly as at 94, thence over as at 96 andthence inwardly as at 93 for providing an elongated U-shaped grooveinto'which flange 92 of a similar adjacent panel is receivable. Theouter face of leg 98 abuts end wall 74 of channel 70, being securedthereto by suitable fastening means, such as a metal screw 100, Fig. 2,which passes through flange 92, and legs 94 and 98 of the U-shapedgroove of an adjacent panel for providing an interlocked rigidconnection.

The ceiling and side wall constructions are similar. In the ceiling, aplurality of channels 70 are provided lengthwise of the unit, see Figs.1 and 2, the ends of said channels engaging ledge-forming horizontalchannel leg 89. The elongated panels denoted by the numeral 98 in Pig. 2are similar in all respects to panels 86 of the side walls. The sidesand ends of panels are provided with flanges and U-grooves, the same aspanels 86, as evidenced by use of similar numerals. It will be notedthat the ceiling panels may be secured in place by means of fasteningmembers 97.

In the preferred embodiment of the invention, I provide a window opening99 and a storage-space opening through certain of the side walls. Suchopenings, the storage-space being denoted generally by the numeral 110,Figs. 3 and 5, are fabricated by providing an outturned lip 112 in aside wall panel 86, wherein the end of lip 112 is turned outwardly as at114 for providing a flange. -t should be understood that the side walls113 of the storage space 10 are likewise formed by being foldedoutwardly in a plane at substantial right angles with the main plane ofpanel 86 in a manner similar to lip 112. The ends of walls 118 areturned outwardly to provide a flange 115, Fig. 3. A backing member 116fabricated from a piece of suitable sheet material may be securelyattached to flanges 114 and 115.

Substantially the same construction may be followed in forming aWindow-receptive opening, it being noted that similar portions of thewindow opening and linen storage compartment have been given the sameidentifying numbers in Figs. 3 and 4, wherein Fig. 4 relates soley to awindow construction.

As disclosed in Fig. 4, the outer peripheral mounting flange 120 of acasement window of any standardized construction may be secured tooutturned flanges 114 and by suitable fastening means indicatedgenerally by the numeral 122. The window construction will have a sillmember defined by lip 112 free of joints or other crevices into whichwater, vapor or other penetrable substance may enter.

From the foregoing, it will be noted that the resultant cubicalstructure comprises a reenforced base elemerit, a floor, side walls andceiling. Suitable plumbing fixtures, such as, a bathtub 192, toilet 104,washstand 14 soap dishes 142, towel bars 144, tissue holder 146,medicine cabinet 148, may be placed within the room.

lreferably all of the plumbing connections are made through a commonside wall, the one adjacent utility shaft 48.

As best disclosed in Fig. 6, hot and cold water pipes 154) and 152,respectively, may be installedfor servicing the bathtub 102, shower head103, toilet 104 and washstand 145. Each of these pipes may terminate inlengths of downwardly projecting portions, the lower ends of whichpreferably extend below elementS-i of the base member 26 therebyfacilitating ease of access thereto by the plumber, after the unit roomhas been integrated into the building structure.

With reference now to Figs. 5 and 6, it will be noted that a fitting179, such as, by way of example, a T

connection, crow foot, double outlet T, or triple outlet T, may beoperatively connected to a conventional closet ring 172 by means of abend 174. Fitting 170 is preferably secured to and carried by the basemember by suitable clamps suc as are denoted by the numerals 175 and177. By thus providing outlet 17% in fixed relationship with referenceto the unit the vertical leg of the outlet may be used as a template foraccurately locating the position of stack, vent or drain pipes to beconnected thereto.

After the hot and cold water pipes 15% and 152 have been connected tosupply pipes and proper connections made with fitting 170, the room maybe entered for the first time when it becomes necessary or desirable topressure-test the drain line. This may be done by removing the toiletfixture for exposing closet ring 172. A suitable plug is introduced intothe exposed end of bend 174 for enabling the drain connection to betested for leaks. After the test has been completed the plug is removedand the toilet replaced whereupon the bathroom is eady for use.

In those instances where the wall and ceiling panels are of sheet metalregular automobile paint may be spray applied for providing anattractive, durable finish.

With reference to Fig. 3, it will be noted that an adjoining wall 117may be erected along that side of utility shaft 40 remote from theadjacent wall of the unit. Wall 117 completes the utility shaft whichmay be utilized to accommodate other service lines, such as heat, power,telephone, water, drainage and the like.

In Fig. 7, I have illustrated the ease with which the walls of my unitmay be insulated. The numeral 156 denotes generally a barrier elementfabricated, if desired, from an open mesh wire suitably fastened tochannels 70. Insulating material 152 may be placed between the outerface of side panels 86 and barrier element 150, as illustrated. Suchinsulation is beneficial from a heating insulating as well assoundproofing standpoint, although highly satisfactory results may beobtained when the insulation is omitted.

What is claimed is:

1. A prefabricated bathroom unit associated with and spanningly engagingat least three sides of a room-supporting, well-defining structure, saidunit comprising a load-bearing, support-spanning, substantiallycontinuous base member including horizontal legs which overlappinglyengage the upper portions of the sides of said structure, and verticallegs depending therefrom adapted to be received within said structure inclose proximity with said sides of said structure, vertical channels thelower ends of which are secured to and carried by those portions of saidhorizontal legs remote from said vertical legs, a floor spanning saidbase member and overlappingly engaging those portions of said horizontallegs substantially over said vertical legs, side walls suspended fromthe tops of said vertical channels, the bottom edges of said side wallsterminating adjacent said horizontal legs between said vertical channelsand the edges of said floor.

2. A prefabricated bathroom unit associated with and spanningly engagingat least three sides of a room-supporting, well-defining structure, saidunit comprising a load-bearing, substantially continuous base memberincluding horizontal legs the outer portions of which engage the upperportions of sides of said structure and vertical legs depending from theinner portions of said horizontal legs adapted to be received withinsaid structure in close proximity with said sides of said structure, abase channel secured to and carried by the outer portions of saidhorizontal legs, said base channel including upwardly projecting innerand outer flanges, vertical channels received between said upwardlyprojecting flanges and secured to and carried by said base channel, sidewalls the upper ends of which are suspended from said vertical channelsand the lower ends of which are received between the adjacent faces ofsaid vertical channels and said inner upwhich engage the upper portionsof the sides of said structure and vertical legs depending from theinner portions of said horizontal legs adapted to be received withinsaid structure in close proximity with said sides of said structure, asubstantially U-shaped base channel, including laterally spaced,upwardly projecting inner and outer legs, secured to and carried by theouter portions of said horizontal legs, vertical channels, eachincluding an end wall and laterally spaced inner and outer legsprojecting therefrom, said vertical channels being carried by, andreceived between the inner and outer legs of said base channel, theouter legs of said vertical channels being secured in face-to-faceengagement with the outer leg of said base channel providing elongatedslots between adjacent faces of the inner legs of said vertical channelsand the inner leg of said base channel, a substantially continuous anglemember extending around the upper ends of said vertical channels, saidangle member including a horizontal leg overlappingly engaging said endsof the vertical channels and a vertical leg depending therefrom securedadjacent to the outer surfaces of the outer legs of said verticalchannels, side walls comprising elongated panels the upper ends of whichterminate in outwardly projecting flanges adapted to overlappinglyengage the horizontal leg of said angle member for suspending saidpanels from said angle member, means securing said flanges to saidhorizontal leg of the angle member, adjacent vertical edges of saidpanels being provided one with an outturned flange and the other with aU-shaped groove dimensioned to receive said outturned flange forproviding a complementary interlocking means for said panels, saidinterlocking means being secured to the end walls of the verticalchannels for holding the panels adjacent to and in substantialparallelism with the inner legs of said vertical channels for providinga rigid, reinforced, continuous wall, the lower ends of said panelsbeing complementarily received in the slots between adjacent faces ofthe inner legs of the vertical channels and the inner leg of the basechannel, rigid cross members secured to and spanning opposite topportions of the vertical legs of said base member, the top surfaces ofsaid cross members being in substantially horizontal alignment with thetop surface of the horizontal leg of said base member, a floor spanningsaid base member over and in engagement with said cross members andoverlappingly engaging the inner portions of the horizontal legs of saidbase member, said floor terminating adjacent that surface of the innerleg of the base channel remote from said panels.

References Cited in the file of this patent UNITED STATES PATENTS 28,295OBrien May 15, 1860 628,579 Ennis July 11, 1899 1,556,565 Walsh Oct. 6,1925 1,730,547 Wallace Oct. 8, 1929 1,978,842 Hooton Oct. 30, 19342,087,121 Samelow July 13, 1937 2,131,124 Smith Sept. 27, 1938 2,272,910Gobberdiel Feb. 10, 1942 2,343,896 Fishko Mar. 14, 1944 2,562,050Lankton July 24, 1951 OTHER REFERENCES Architectural Forum, September1947pages 119 and 120.

